Energy-Efficient Peak-Current Controlled Power Conversion IC Family Delivers 3 to 28 Watts in Universal-Input Flyback Power Supplies By Kent Wong and John Jovalusky APEC 2007 Anaheim, California Scope of Paper and Presentation • Introduction of IC control scheme concept and its benefits • IC operation and power supply interaction • Defining the state machine state-change criteria and limits • Descriptions of IC pin functionality & important internal functions • Power supply performance results • Conclusion APEC 2007 Session T8: Semiconductor Devices Slide# 2 Introduction: Basic IC Functionality • ON/OFF control enables/disables MOSFET switching cycles • Since MOSFET & controller are integrated, IDRAIN is sensed directly • Enabled cycle switch on-time ends when IDRAIN reaches ILIMIT APEC 2007 Session T8: Semiconductor Devices Slide# 3 Basic Functionality Continued: State Machine Operation and Supply Stability/Responsiveness • State machine adjusts ILIMIT based on number of consecutive enabled or disabled cycles • Pole-zero placement, slope compensation and gain/phase bode plotting are eliminated • Transient load responsiveness is fast yet stable, and equal to or better than that of a well compensated PWM controlled power supply APEC 2007 Session T8: Semiconductor Devices Slide# 4 Overview of How IC Interacts with Power Supply • VOUT is compared to a reference (Zener Diode) • When VOUT > ref set-point, Zener and opto-LED conduct, phototransistor pulls current from EN/UV pin, which disables switching • As switching cycles are skipped, VOUT drops below ref set-point, Zener and opto-LED stop conducting…, which enables switching Controller continually enables/disables MOSFET switching to keep VOUT in regulation APEC 2007 Session T8: Semiconductor Devices Slide# 5 State Machine Operational Overview & Benefits • Since cycles are skipped while VOUT > the reference set point, ON/OFF control realizes very low no-load power consumption • The state machine automatically adjusts the MOSFET ILIMIT according to the load – (ILIMIT is raised as the load increases and lowered as the load decreases) APEC 2007 Session T8: Semiconductor Devices Slide# 6 Defining State-Machine State-Change Limits • Frequency boundary between CCM and DCM operation – The boundary frequency between CCM and DCM operation of a peak current limited, ON/OFF controlled, flyback converter is determined by the steady-state minimum inductor current (IMIN) as a function of ILIMIT (1) I min = I LIMIT − (1 − D)TS Vo (V T − L( I LIMIT − I min ))VoTs T V = I LIMIT − in S = I LIMIT − s ( O || VIN ) nL L n LVinTs L L nL – where 1:nL is the transformer primary to secondary turns ratio, Ts is the switching period (1/frequency), L is the primary winding inductance value, VIN and VO are the input and output voltages and D is the duty cycle. Solving for the inductance at which IMIN = 0 gives the CCM/ DCM boundary, and yields the critical switching frequency value of (2) f crit = 1 VO || VIN ) I LIMIT L nL ( APEC 2007 Session T8: Semiconductor Devices Slide# 7 State-Machine State-Change Limits, continued • Power Delivery in DCM versus CCM – Power delivery in DCM is simply (3) PO , DCM = – (4) 1 2 LI LIMIT f s 2 When operating in CCM, power delivery is a little more complex PO ,CCM = VO I O = VO (1 − D) I LIMIT + I min 1 VIN I + I min V V ( ) = VO ( )( LIMIT ) = ( O || VIN )[ I LIMIT − ( O || VIN )( )] 2 2 2 Lf s nL nLVIN + VO nL nL – When a switching cycle is skipped in CCM and steady state operation ceases, ^ the inductor current perturbation, iL (0) , must be taken into account. Thus, the inductor current, I min − p (i) , at the end of the cycle following the skipped cycle is ^ (5) I min − p ( i ) = I min + i L ( 0 ) ( − Vo )i = I n L V in LIMIT − Ts VO ( || V L nL ^ IN ) + iL (0 )( − Vo )i n L V in and the power delivered in a train of^ m CCM switching cycles in time (m+1)Ts following a perturbation, i L (0) , would thus be (6) PO ,CCM m m ^ L L Ts V0 V0 i 2 2 2 2 = I − I i = mI − I − V + i ( ( )) [ ( ( || ) ( )) ] ∑ ∑ LIM min − p LIM LIM IN L 0)( − L n n V 2(m + 1)Ts i =1 2(m + 1)Ts i =1 L L IN APEC 2007 Session T8: Semiconductor Devices Slide# 8 Defining State Machine State-Change Criteria Case DCM only DCM @ min fs CCM @ max fs CCM only Power & fs are minimum. Pertinent to the intermediate and the full ILIMIT states Power delivery and fs are at a maximum. Pertinent to the intermediate ILIMIT states and the lowest ILIMIT state One switching cycle followed by (n − 1) skipped cycles, f s = ( 1 ) f clk , uses Equation 3: n ( n − 1) switching cycles followed by one skipped cycle, n −1 fs = ( ) f clk , uses Equation 3: n 1 1 Pmin = ( ) LI n 2 Pmax = ( 2 LIM − state f clk One switching cycle followed by (n − 1) skipped cycles, f s = ( 1 ) f clk , uses Equation 3: n Pmin 1 1 = ( ) LI n 2 2 LIM − state f clk One switching cycle followed by (n − 1) skipped cycles, but IL ≠ zero, even during ( n − 1) skipped cycles. ∴ converter is always in CCM, f s = ( 1 ) f clk , uses Equation 4: n Pmin = ( VO V n || VIN )[ I LIM − state − ( O || VIN )( )] nL 2 Lf clk nL n −1 1 2 ) LI LIM − state f clk n 2 ( n − 1) switching cycles followed by one skipped cycle, in CCM (involves accounting for the perturbation as a result of the skipped cycle), uses Equation 6: Pmax = n −1 ^ T V V L 2 − ∑ ( I LIM − s ( 0 || VIN ) + i L (0)( − 0 ) i ) 2 ] [(n − 1) I LIM 2(n)Tclk L nL n LVIN i =1 ( n − 1) switching cycles followed by one skipped cycle, in CCM (involves accounting for the perturbation as a result of the skipped cycle), uses Equation 6: Pmax = n −1 ^ T V V L 2 − ∑ ( I LIM − s ( 0 || VIN ) + i L (0)( − 0 ) i ) 2 ] [(n − 1) I LIM 2(n)Tclk L nL n LVIN i =1 fclk is the internal IC oscillator (clocking) frequency APEC 2007 Session T8: Semiconductor Devices Slide# 9 State Machine State-Change Criteria Depicted APEC 2007 Session T8: Semiconductor Devices Slide# 10 IC Pin Function Descriptions • DRAIN (D) Pin: – Power MOSFET drain and high-voltage current source (start up circuit) connections • BYPASS / MULTI-FUNCTION (BP/M) Pin: – Bias supply bypass capacitor connection point – Internal ILIMIT level selection function – Input for latching shutdown function • ENABLE / UNDER-VOLTAGE (EN/UV) Pin: – Feedback input to switching controller – Input for under-voltage lockout function • SOURCE (S) Pin: – Power MOSFET source connections and controller ground reference point APEC 2007 Session T8: Semiconductor Devices Slide# 11 Internal IC Circuitry and Functionality Produces and regulates IC’s supply voltage. Eliminates external start-up resistor string Sets voltage level used by comparator to detect ILIMIT Internal ENABLE signal determines if next cycle is skipped or not Voltage across MOSFET D-S detects ILIMIT Prevents the initial current spike from falsely triggering the ILIMIT comparator APEC 2007 Session T8: Semiconductor Devices Slide# 12 Flyback Converter Designed Around the IC APEC 2007 Session T8: Semiconductor Devices Slide# 13 Power Supply Performance Results: Efficiency APEC 2007 Session T8: Semiconductor Devices Slide# 14 Power Supply Performance Results: No-load Power Consumption without a Bias Winding APEC 2007 Session T8: Semiconductor Devices Slide# 15 Power Supply Performance Results: No-load Power Consumption with a Bias Winding APEC 2007 Session T8: Semiconductor Devices Slide# 16 Power Supply Performance Results: Transient Load Response APEC 2007 Session T8: Semiconductor Devices Slide# 17 Power Supply Performance Results: Conducted EMI APEC 2007 Session T8: Semiconductor Devices Slide# 18 Conclusion • Integrating a high-voltage MOSFET with a simple controller: – Shortens the duration and the cost of the design process – Enables the integration of functionality that is otherwise impossible • ON/OFF control and the state machine give the following benefits: – Consistently high active-mode efficiency over the entire load range – Very low light load and no-load power consumption – Delivers optimized responsiveness without the loop compensation exercise – Eliminates audible sound production at no-load and light loading • Careful Modeling of state machine state-change criteria and limits: – Minimized the number of ILIMIT levels required & kept change criteria simple – Enabled excellent transient load response without unnecessary state changes • Power supply performance results show that the concept is sound – Low cost, good performing power supplies can be quickly designed APEC 2007 Session T8: Semiconductor Devices Slide# 19